Fluid power at sea p. 30
Sustainability makes waves in WorkBoat Show p. 35
How connected pneumatics benefit manufacturers p. 39
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October 2023
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FLUIDLINES Mary C. Gannon • Editor-in-Chief
Are pneumatics at risk of becoming obsolete? Last month, I had the pleasure of attending Pack Expo in Las Vegas for the first time in about five years. I’ve always enjoyed that show, seeing all the packaging machinery and conveyors operating, watching the pneumatics and motion control technologies do what they do best. But I did notice one thing this year — a lot of companies are pushing electric and mechanical options more so than ever, noting that they’re moving away from compressed air and pneumatic control because of efficiency issues. Even legacy pneumatics companies had a big push for their electric solutions. At Festo, they were showing a canning/packaging machine from Codi Manufacturing that was converted from all-pneumatic control to almost completely electric, apart from the vacuum grippers used to place the fourpack cardboard holders onto the cans. (Stay tuned for a full story on this machine in a later issue). Mike Hoffman, manager of enginieerinig from Codi said the need for quick changeovers and less downtime was the initial reason behind the push to move to electric actuation. But when they saw that the actions were more controlled, had less violent motions, and were more efficient, it was a no-brainer to remove the pneumatic valves. Over at Coesia, a manufacturer of packaging machinery, I had a chance to view several machines running both pneumatic and electric control systems. There, they switched one of their main compressed air systems to a vacuum pump because, once again, compressed air leakage and inefficiency were a concern. (Again, stay tuned for more information on Coesia’s systems.) This seems to be a recurring theme lately. Clearly, there has been a noticeable shift in industrial and automation technologies in recent years, with electric actuation steadily replacing pneumatics in various applications. Should we be concerned about pneumatics becoming obsolete? No. And here’s why: just like hydraulics, pneumatic technologies still have cost-effectiveness, durability, and density on their side. As I was drafting this commentary, I just happened to stumble upon a live LinkedIn presentation by Dr. Elvira 2
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Rakova, CEO at DIREKTIN, which offers a platform to reduce energy consumption of compressed air systems. She admitted that yes, in certain circumstances, electric actuators are the way to go, especially when multiple velocities and cycles are required. But when looking at long-term costs and maintenance, pneumatics will almost always win out as the less costly option and the one that’s easier and cheaper to maintain and fix. The caveat here, she said, is in sizing and selection. It is crucial to right-size your components, particularly your cylinders, to ensure an efficient operating system. It’s just as crucial to maintain and manage these systems with modern technology. Compressed air is still a cheap commodity, but if it’s not monitored and used wisely, it could cost you thousands of dollars more than necessary. While the transition to electric systems offers undeniable advantages, it is crucial to recognize that pneumatic technologies still hold their own, offering unique benefits and cost-effectiveness that cannot be easily dismissed. Pneumatic systems are inherently simple and robust. They can withstand some of the harshest environments, such as washdown and highspeed, repeatable processes, which can cause vibration and damage electric actuators. Sometimes, they are the only option where electrical spark or flammable risks are present. Throughout this issue, and in every issue of Fluid Power World, you will find several articles highlighting opportunities to increase compressed air efficiency, manage leakage, and right-size your system components. Be sure to turn to pages 12, 24, and 39 to learn how to optimize your compressed air and automation systems. And as always, visit pneumatictips.com for new content each week.
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Mary C. Gannon • Editor-in -Chief mgannon@wtwhmedia.com On Twitter @FPW_marygannon
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FROM THE FIELD Paul J. Heney • VP, Editorial Director
Fluid power & diversity
At
At a recent National Fluid Power Association event,
one of the panel discussions centered around diversity issues when hiring talent. Robin Carter-Cooper, global director of diversity, equity, inclusion, and talent at Danfoss Power Solutions, noted one of the difficulties for companies to get DEI practices right. “When we’re trying to strategize on obtaining diverse candidate pools, we typically have the same people sitting at the table, wracking our brains trying to figure it out,” said Carter-Cooper. “When you know that you have a gap in your talent, go seek out that talent, that community, and ask them. It sounds so simple, but it’s such a missing step. It’s engaging the voices that you want in your organization, ‘Why are you not here? What can we do to get you? What are we missing?’” Earlier this year, our parent company, WTWH Media, sent a DEI survey to readers of its engineering publications (including Fluid Power World) to get a pulse on where the design engineering industry is. One encouraging statistic from the survey was that many respondents (70%) felt comfortable speaking up about DEI issues at work. However, more than half of the respondents (55%) admitted to witnessing or experiencing discrimination or bias — a grim reminder that, despite progress, prejudice does persist. What’s more, there was a minor but vocal undercurrent of comments that were outwardly hostile, conflating DEI initiatives with racism and the hiring of inexperienced people. “I understand that change, in general, can be challenging or uncomfortable,” said Cheyenne Ray, manager of diversity, equity, and inclusion at Fortune Brands Home and Security. “I think the pushback we hear in the news or see on social media is a loud minority. However, I would challenge people who do not yet see the value in DEI to really understand what DEI work is about. The purpose of DEI work is to create an environment where everyone feels they belong and can do their best work. There are companies out there, including ours, that are thriving in this space.” “Diverse engineering teams bring a variety of skills and experiences together that fosters innovation,” said Philip Anderson, chief diversity officer and director of
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the Leadership Institute at Argonne National Laboratory. “It allows the entire team to draw on the different experiences of each member. It gives them the power to expand their thinking beyond just one perspective ... diverse members give teams access to the next level of thinking that helps solve complex problems.” Anderson also thinks that diversity is important not only for manufacturers, but any business that relies on people to manufacture, sell, or buy their products or services. Plus, there’s an argument to be made for keeping top talent. “People are motivated by a sense of belonging, by a sense that what they do has value,” he said. “The adage that people don’t leave companies — they leave managers — is true. If any company wants to attract and keep the best and brightest, they must ensure a safe, equitable, and inclusive work environment. The concepts of diversity, equity, and inclusion apply to all employees, not just those in the minority. Additionally, if they want to sell their products or services, they must understand the people who buy them — and those people are becoming more diverse. Diverse practices help companies gain insight into what is important to a diverse population by tapping into what motivates them.” Anderson noted that employee surveys, focus groups, interviews, or listening sessions can help you understand your current DEI gaps. “Find experts with organizational change experience to help you develop targeted solutions based on the data you collected,” he said. “Along the way, ensure what you put in place is working by communicating as often as possible. Then, finally, go back and evaluate whether those solutions worked. If you find they didn’t, don’t give up. Just take further action until they do. Once you start, you’re in it for the long haul. DEI is a journey, not a destination.”
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Paul J. Heney
VP, Editorial Director pheney@wtwhmedia.com
On Twitter @wtwh_paulheney
OCTOBER 2023
C ontents | v o l 1 1 n o 7 |
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F E AT U R E S FLUIDS IN MARINE
Eco-friendly shipping is possible with EALs The global shipping and marine industry is, like all industries, pursuing new ways to become more environmentally friendly. The use of environmentally acceptable lubricants (EALs) can make a major impact in that push.
MARINE HYDRAULICS
Fluid power at sea Learn how hydraulics are used in maritime vessels and why hydraulics is the technology of choice.
WORKBOAT SHOW PREVIEW
Sustainability makes waves in WorkBoat Show The International WorkBoat Show highlights sustainability efforts as it returns to the Morial Convention Center in New Orleans, November 29 - December 1.
PNEUMATICS
Understanding connected pneumatics and how they benefit manufacturers In future, updating pneumatic circuits through the IoT will help manufacturers stay current and benefit from the opportunities available to them.
MOBILE MATERIAL HANDLING
Material handlers lead the charge to the future Material handling machines lead the pack in terms of electrification and autonomy, as their compact designs are a perfect fit to test out sustainable options.
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D E PA R T M E N T S
02 FluidLines
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04
From the Field
08
Perspectives
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Association Watch
12
Design Notes
20 Fundamentals
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ON THE COVER
22
Component Focus
24
Energy Efficiency
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Products
47
Ad Index
48
Troubleshooting Challenge
The global shipping industry is using more Environmentally Acceptable Lubricants to be more sustainable. | Courtesy of Lubrizol
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2023
2023
BRONZE REGIONAL AWARD
BRONZE REGIONAL AWARD
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OCTOBER 2023 • vol 11 no 7 • www.fluidpowerworld.com
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FLUID POWER WORLD does not pass judgment on subjects of controversy nor enter into dispute with or between any individuals or organizations. FLUID POWER WORLD is also an independent forum for the expression of opinions relevant to industry issues. Letters to the editor and by-lined articles express the views of the author and not necessarily of the publisher or the publication. Every effort is made to provide accurate information; however, publisher assumes no responsibility for accuracy of submitted advertising and editorial information. Noncommissioned articles and news releases cannot be acknowledged. Unsolicited materials cannot be returned nor will this organization assume responsibility for their care. FLUID POWER WORLD does not endorse any products, programs or services of advertisers or editorial contributors. Copyright© 2023 by WTWH Media, LLC. No part of this publication may be reproduced in any form or by any means, electronic or mechanical, or by recording, or by any information storage or retrieval system, without written permission from the publisher. SUBSCRIPTION RATES: Free and controlled circulation to qualified subscribers. Non-qualified persons may subscribe at the following rates: U.S. and possessions: 1 year: $125; 2 years: $200; 3 years: $275; Canadian and foreign, 1 year: $195; only US funds are accepted. Single copies $15 each. Subscriptions are prepaid, and check or money orders only. SUBSCRIBER SERVICES: To order a subscription please visit our web site at www.fluidpowerworld.com FLUID POWER WORLD (ISSN 2375-3641) is published seven times a year: in February, April, June, July, August, October, and December by WTWH Media, LLC; 1111 Superior Ave., Suite 2600, Cleveland, Ohio 44114. Periodicals postage paid at Cleveland, OH & additional mailing offices. POSTMASTER: Send address changes to: Fluid Power World, 1111 Superior Ave., Suite 2600, Cleveland, OH 44114
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PERSPECTIVES Rachael Pasini • Senior Editor
Today’s solutions are tomorrow’s problems Engineering is a never-ending problemsolution spiral. That’s honestly one of the things I love about it. Solutions adapt proactively and reactively as the world evolves and technologies and materials advance. There’s always a new challenge, a new regulation, a new crisis, or a shift in human perspective or behavior that prompts change. I recently interviewed Eileen Collins, retired U.S. Air Force colonel and NASA astronaut and the first woman to pilot and command a space shuttle mission. Hearing her story about problem-solving in space and mission control was beyond inspiring and gave me chills. The types of challenges she faced — and the intense preparation, knowledge retention, critical thinking, and confident decision-making in the face of dire uncertainty — seem superhuman to me. (You can read her story in the October 2023 Engineering Diversity & Inclusion issue of our sibling publication, Design World.) “Don’t run away from problems,” she said. “Don’t fear problems but see them as a challenge… there’s a solution to everything.” So true and so relevant to the fluid power industry today. In another interview, Peter McCurry, managing director of Flowcopter, admitted that many believe hydraulics is a sunset industry — a gracious way of saying it’s going the way of the dodo. But anyone in fluid power knows that’s far from accurate. For example, Howard Zhang and Rich Nagel of Parker Hannifin recently presented a Fluid Power World webinar on integrated ePumps that help OEMs on their electrification journeys. Nothing beats the high-power density of hydraulics, and we’re a long way off from compact, lightweight batteries that deliver the same. Flowcopter’s McCurry agrees, which is why his team chooses to optimize hydraulic technology for aerial applications. (You’ll learn on page 19 how Flowcopter uses hydraulics with humanitarian aid delivery in mind.) As Zhang and Nagel shared in the webinar, Parker Hannifin’s ePumps are hydraulic pumps integrated with high-speed motors that can be 8
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tailored to applications and enhance control features with real-time data for diagnostics and predictive maintenance. The design adds knowledge to power so owners and operators get the most bang for their buck. But this solution exists because we’re facing a huge problem — environmental sustainability. Yet the solution also creates new problems of its own. For instance, thermal management challenges emerge and are critical to component life cycles. And when you get rid of a diesel engine, the hydraulic pump becomes the noisiest component. Carbon-free policies and local emissions and noise regulations drive integrated system innovations, and the solutions spark a whole new set of design considerations that evolve the system into something completely different. And here’s the kicker: no single company will revolutionize fluid power solo. Sure, everyone’s racing to get new products to market to get ahead on sustainability-related profits. But as was the theme of SICFP 2023, it will take the entire industry to gain new knowledge, think differently, and move confidently toward uncertainty to solve today’s most pressing problems — problems that will inevitably inspire ingenious solutions that create future challenges. Some fluid power problems, especially the ones that give it a bad rep, have remained unsolved because it hasn’t been profitable to address them. Now, the pressure’s on, and the world is in a time crunch. But as NASA astronaut Eileen Collins says, “There’s a solution for everything.” And fluid power still has a big role to play.
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Rachael Pasini
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ASSOCIATION WATCH Edited by Mary C. Gannon • Editor-in-Chief
IFPS announces new board leadership, additional digital offerings Last month, the IFPS met for its annual
•
meeting in Milwaukee, where it made several major announcements to benefit members and the industry in general. Firstly, a new board was elected. Jeffrey (Jeff) Hodges, CFPAI, CFPAJPP, CFPMHM, was elected 2024 president and chair. He is the 64th president of the IFPS and will take office along with the 2024 Board of Directors in January 2024. Hodges began his career at a small commuter airline as an Airframe and Power Plant (A&P) mechanic; after a few years at the airline, he decided to venture into managing a small engine repair shop. In 1995, he made a significant career move by joining Altec. During his initial five years with the company, he served as a Mobile Service Technician before transitioning to Shop Service, where he contributed his skills and expertise for an additional seven years. During his early years at Altec, Hodges was inspired and guided by his mentor, Willie Franke, to attain the IFPS Mobile Hydraulic Mechanic Certification. Once he successfully acquired this certification, he became enthusiastic about assisting his colleagues at Altec in their certification journey. This enthusiasm led him to transition into the training department, where he further honed his skills and attained the status of an IFPS Accredited Instructor and Job Performance Exam Proctor. Hodges has continued to excel in Altec’s training department for the past 16 years, and he attributes much of his accomplishments to the invaluable mentorship he received from Willie Franke. The following officers were also confirmed at the meeting: • First Vice President - Garrett Hoisington, CFPAI/AJPP (O) Altec Industries, Inc. 10
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• •
•
• •
Immediate Past President – Scott Sardina, PE, CFPS, CFPAI, CFPECS, Waterclock Engineering Treasurer - Elisabeth DeBenedetto, CFPS, GS Global Resources Vice President Certification – James O’Halek, CFPAI/AJPP, CFPMIP, CMPMM, The Boeing Company Vice President Marketing and Public Relations - Chauntelle Baughman, CFPHS, OneHydraulics Inc. Vice President Education - Daniel Fernandes, CFPS, Hawe Hydraulics Vice President Membership – Brian Wheeler, CFPAI/AJPP, The Boeing Company
IFPS welcomes the following new Directors-At-Large: • Jeff Curlee, CFPS, Cross Mobile Hydraulics & Controls • Deepak Kadamanahalli, CFPS, CNH Industrial • Steven Downey, CFPAI, CFPS, Hydraulex • John Juhasz, CFPS, Kraft Fluid Systems The following Directors-at-Large were reconfirmed during the annual meeting: • Wade Lowe, CFPS, Hydraquip Distribution Inc. • Cary Boozer, CFPE, Motion Industries Inc. • Jon Rhodes, CFPAI/AJPP, CFC Industrial Training • Bruce Bowe, CFPAI/AJPP, Altec Industries Inc. • Ethan Stuart, CFPHS, Quadrogen • Brian Kenoyer, CFPS, Cemen Tech • Stephen Blazer, CFPE, Altec Industries Inc. • Bradlee Dittmer, CFPPS, Norgren Two Ex-Officio officers were also reconfirmed during the annual meeting: • CEO, Donna Pollander, ACA • Honorary Director-at-Large, Ernie Parker, Hydra Tech Inc. CFPAI/AJPP www.fluidpowerworld.com
Additionally, the organization recently announced that the second edition of its Fluid Power Reference Handbook will be released digitally. The digital edition will be a go-to reference for all things fluid power and will be easily searchable for quick access to information. The organization is also offering online, self-paced certification training modules. Available topics include fluid power math, hydraulic mechanic, hydraulic specialist, pneumatic specialist and connector & conductor. Visit IFPS.org for more information.
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NFPA suggests best practices for recruiting students The NFPA Education and Technology Foundation seeks to increase the number of technical college and university level students educated in fluid power and connect NFPA members with opportunities to recruit them. The students who participate in workforce programs have a genuine interest in fluid power and valuable hands-on experience that many employers are seeking. To help NFPA members make the most of these recruitment opportunities, NFPA has put together this list of easy-to-follow tips. 1.
2.
3.
4.
5.
Schedule a time to speak to a class, a Vehicle Challenge team, or a Fluid Power Club. There are more than 20 universities involved in these programs and NFPA’s Workforce Team can assist in making these arrangements. • Show applications, markets served, and demonstrate to students how the work they will do makes an impact. Join a NFPA Workforce Engagement Group to connect with the Power Partner universities and Fast Track Hubs. These educational institutions teach fluid power and actively coordinate with NFPA to connect their student population with NFPA members for youth career exploration and recruiting sessions. Workforce Engagement Groups will represent Illinois, Indiana, Iowa, Kentucky, Michigan, North Carolina, Ohio, Texas, and Wisconsin. Participate in the Fluid Power Vehicle Challenge (FPVC), a multidisciplinary design/build program designed for engineering students to learn about fluid power applications and careers. • Register on the NFPA Foundation website and create a company profile with relevant information.* • Invite HR and an engineer to staff a virtual table during the FPVC virtual Networking Mixer and plan to follow up with interested students. * • Invite an HR representative to attend at least one FPVC mentor meeting and/or attend the Final Competitions. This allows for them to meet the students and see first-hand how they work together as a team and tackle challenging project elements.* Review NFPA’s Fast Track and Power Partner schools and encourage alumni at your company to get involved in Workforce Programs that interest them. Recent alumni are the most equipped to speak about their educational experience and career path into our industry. Encourage HR and Technical/Sales/ Engineering staff to promote career opportunities when speaking with students. Students are often unfamiliar with fluid power technology and do not understand the detail of the role and what to expect day-to-day.
6.
Notify NFPA of internships, co-ops, job shadowing, and rotational programs. Consider recruiting freshmen and sophomores as well as upperclassmen into these roles and when possible, share details upfront about relocation benefits. 7. Use NFPA’s Workforce Programs as a staff team building or community impact initiative and engage with youth and emerging talent in a community near you. *Participation in the Fluid Power Vehicle Challenge events is restricted to Pascal Society Donors.
Career Fair Recruitment Tips: 1. 2. 3.
4.
5. 6. 7. 8. 9.
Familiarize yourself with the Career Services offices. Some schools have specific career services offices for Engineering. Find out which student-recruitment app the school uses (like Handshake) and set up an account. Schedule a meeting with the Career Services Office to get questions answered, reserve interview space, meet relevant faculty, and learn more about the services they offer to employers. Consider hosting an informational session with a student organization, like a fluid power club, and post job openings on the school’s student recruitment app. Reach out to students through the app or LinkedIn, and invite them to visit your booth at the fair. Share direct links to your job postings. Send reminders to targeted majors, invite faculty to meet you at the career fair, and check in with the event organizers. On the day of, arrive early, be engaged, ensure you always have personnel at the booth. Host an after-hours event, schedule interviews, and follow-up communications. If you cannot participate in a career fair, talk with the career services office about other ways they can help you connect with students.
For more information, contact Stephanie Scaccianoce at sscaccianoce@nfpa.com.
www.fluidpowerworld.com
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DESIGN NOTES Edited by Rachael Pasini • Senior Editor
Finding energy efficiency in the cloud Every manufacturer using compressed air shares the challenge of keeping compressed air systems running efficiently and reliably. Depending on the industry, the compressed air system accounts for 10 to 50% of a plant’s energy usage and is as essential to uptime as electricity. But compressors are inherently inefficient. Leakage, irregular maintenance, pressure settings, and controls contribute to energy inefficiencies. In many cases, modernizing and integrating obsolete systems with IoT solutions uncover potential energy savings from 25 to 50%. “We’ve been in business for over 30
years, doing energy savings via automation for most of that time and focusing on compressed air for the last 25 years plus,” said Lou York, director of business development at CaseiZ. “The driver behind the Internet of Things is using the latest tools available to provide our customers with the information they need to make decisions and even help facilitate some of that decision-making for them.” CaseiZ collaborated with Rockwell Automation to develop AirView Cloud, a monitoring system based on the ThingWorx IIoT platform that connects disparate devices, applications, and data streams to enable secure access to industrial operations data. The company’s motivation was to provide its customers — mainly
energy engineers, those who focus on the corporate side of utilities, and plant-level professionals — with a better experience using cloud-based tools. “Everyone has less time to delve through data and do their own analysis,” said York. “So, we’re taking these tools and providing good information and very clear information from that data. We’re doing some of that analysis piece for them as well.” Previously, CaseiZ generated static PDF energy reports that customers could download at the end of each month. By the time customers received the report, the information was outdated and uninformative for current operations. The best they could do was adjust their systems and then wait another month to see if it worked.
CaseiZ uses Rockwell Automation technology
to create integrated cloud-based systems that reduce energy consumption and cost. | Courtesy of CaseiZ
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AirView Cloud is based on the ThingWorx IIoT platform and provides real-time data on compressed air systems. | Courtesy of CaseiZ
“That’s not acceptable these days. We need real-time data and real-time analysis,” said York. “We still summarize things monthly so they can see the history, but we really need to give them more information on a real-time basis. That’s what drove the cloud-based solution.” Into the foreseeable future, energy savings will become more critical with global carbon footprint legislation, net-zero targets, market inflation, and the dynamic supply chain. AirView Cloud allows companies to be more proactive in energy efficiency and take action immediately when KPIs exceed acceptable levels. “In most plants, there’s a lot of existing equipment with individual levels of efficiency. But without it being automated and working together, or even having awareness of how it’s being used, it’s just very wasteful,” said York. A solution such as AirView Cloud is less expensive than replacing all the equipment for underwhelming efficiency gains. And problems can often be solved by optimizing, integrating, and automating current equipment. “Most compressors and compressed air systems that we work on are already electrified. But even then, there’s a degree of waste and inefficiency that automation and optimization can help with,” said York. “IoT and the cloud bring visibility to that because it’s not always clear in the beginning. And the best way to optimize is to be data-driven.” York notes that there’s a push for plants to get rid of compressed air and use electric servos or electric actuators, which improves efficiency but takes a significant capital investment and 10 • 2023
multiple years to complete. Though he supports the effort, York encourages plants to continue prioritizing compressor optimization to avoid wasting energy in the meantime. “It’s very scalable,” said York. “We can piece in the building blocks needed to build a solution, but it also allows us to be very flexible in the future. So, if you want to add more
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machines later, take away machines later; you don’t have to start over. We do implementation with zero downtime, so we can integrate one machine at a time and bring it all together.” FPW
CaseiZ | caseiz.com Rockwell Automation | rockwellautomation.com
DESIGN NOTES By Mary C. Gannon • Editor-in-Chief
Modular hydraulic valves for compact needs The PMV mobile valve PMV-16 is constructed to offer a high level of modularity. It allows a configuration of individual modules, which are available as pre-assembled units with their own type of code. Modifications, to and between them, can also be carried out quickly in the field. Due to the modular design, special solutions can also be created in a flexible manner. For example, counterbalance valves integrated in the connection plate or operated non-return valves can be integrated. By means of the 2-way pressure compensator, the flow can be controlled independent from the load. PMV sectional assembly showing the electrical solenoid control components for automated and proportional functions and the many porting options that can be selected for pressure, return and work ports to optimize the hoses or pipe runs and simplify connections on the unit’s installation.
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PMV valves are used where compact installation dimensions are required and a function requires sensitive control. Typical applications are cylinder and motor controls for all handling functions as in loading cranes, telescopic handlers, aerial platforms, municipal vehicles, construction machinery, drilling equipment, agricultural and forestry machinery, offshore applications, underground mining. Gary Gotting, President & CEO (now retired), Wandfluh of America Inc., noted that the PMV allows for very precise flow control in either direction, either electrically or manually controlled. Wandfluh highlighted this design at IFPE 2023, and the model on display showed how you can easily mix two different sizes of valves — a very large and small one, with a controller — and power beyond feature. “This is basically a brand-new package that has a very, very good pressure compensator, so our pressure compensation is flat throughout,” Gotting noted. “It’s targeting machines where we typically have large flow.” Gotting said that the pressure compensator is extremely linear. While operating the PMV over the entire flow range, you’ll find that it’s providing the exact flow regardless of the load. Wandfluh can offer pre-imposed compensation, which can be added even after you buy the valve. With sectional valves, pre-imposed compensation must be ordered and built into it. Wandfluh can add it as an option later. “So if you buy it and you find you need it, you can have that cost of putting it on later,” Gotting said. “You’re not stuck www.fluidpowerworld.com
PMV sectional assembly demonstrating the compact overall product envelope, ease of access to all user adjustable components, and how easily different flow sections can be combined into one unit to suit the separate flow needs of the application.
with something you either don’t need or you’re not stuck without something that you do need. “Future accessories can easily be fit into the ports. The outlet ports allow you to have electrically operated valves to lock something in place or your driver, you can lock it into place,” Gotting said. “There’s a lot of other accessories as well, like the power beyond which allows you to use the ports on the end to build another small manifold block to do some auxiliary features around this.” It can be electrically and mechanically operated and features mechanical stops to limit the flow mechanically. Pressure return ports on both ends allow you to feed the valve from both sides, said Gotting. But the PMV also features pressure and return in the middle as well, which allows you to run one half of the valve at 210 bar and the half of the valve at 350 bar. “So we’re not wasting energy by driving high pressure and having to reduce it,” Gotting said. Gotting said the modularity allows users to buy exactly what they need. The
*4 *4
fully Wandfluh valve comes with 10 million operations and all the other features that Wandfluh offers. Additional accessories and end plates will grow with user needs. All the published curves in the data sheets come from large, real samples, and 100% of the products are factory tested, so are guaranteed to work. The PMV has been designed specifically to be extremely flexible, to fit all those various market segments that Wandfluh serves. Gotting said this type of functionality, productivity and flexibility has allowed Wandfluh of America to grow 38% as a company last year. “We haven’t gone for the weird and wacky application stuff. We’ve gone for the easiest way to give them the standard stuff. And as with everything else we do, the moment you plug something of ours into an existing hole, there’s an uplift in the performance of the product.
“There’s an immediate change for the operator and a comfort level that comes knowing that with our valve, you have something like a 0.4 and 0.5% difference between valve to valve,” he continued. “So when you start using our product in a series like these, they’re all very tightly toleranced. You don’t have to keep adjusting everything every time and if the operator is moving from machine to machine, it feels the same to them.” Wandfluh offers delivery of 4 to 8 weeks maximum on anything in its catalog, including the new PMV valve. FPW
Wandfluh of America wandfluh.com
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DESIGN NOTES Edited by Rachael Pasini • Senior Editor
Pursuing victory in the America’s Cup The Domin and INEOS Britannia
collaboration marks an exciting milestone in sailing technology, pushing the boundaries of performance in the America’s Cup. | Courtesy of INEOS Britannia
The America’s Cup is one of the world’s most prestigious and oldest sailing competitions. It has a long and storied history, dating back to 1851 when the first race was held around the Isle of Wight in the U.K. The yacht “America” won the trophy, which is how the race got its name. Since then, the race has earned a reputation for intense competition and technical innovation, providing a unique platform for showcasing ground-breaking technology. 16
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Hydraulics play a crucial role in the design and operation of America’s Cup race boats. These high-performance sailing vessels use hydraulic systems to control various aspects of the boat’s configuration and sail control. INEOS Britannia, the Challenger of Record for the 37th America’s Cup in Barcelona next year, has been gearing up to refine its race boat and partner with select manufacturers. Backed by INEOS Founder and Chairman Sir Jim Ratcliffe and led by the world’s most successful Olympic sailor, Sir Ben Ainslie, the team chose Domin’s custom servovalves to lightweight their design. “In the world of competitive sailing, every detail counts. The performance of our www.fluidpowerworld.com
race boat relies on the seamless integration of advanced technologies,” said Ainslie. With reduced weight and improved aerodynamics, the INEOS Britannia gains a competitive edge, increasing its chances of victory in high-stakes races. By minimizing leakage, the Domin servovalves ensure optimal efficiency and control, ultimately reducing energy loss and improving the boat’s overall performance. “Initially, the design requirements were focused on mass, size, and efficiency. Being a high-performance boat, those three factors are key for them. The lighter they can make the boat, the smaller they can make the whole system,” said Jerome Carson, product owner at Domin. “Another requirement was
to raise the pressure in their system so they could use smaller actuators.” Mass and size were easy for Domin, as their standard servovalve design was already light and compact. So, the team prototyped parts quickly in-house to customize valves and meet the boat’s requirements. “We were able to add material effectively and change the design slightly,” said Carson. “We kept very similar machining strategies, so it didn’t take time to reprogram the machining or add new components. We could use the same components in many areas and only change the core manifold.” As for efficiency, traditional two-stage valves are known for leakage, and directdrive valves tend to be bigger and bulkier, making both options less than ideal for the INEOS Britannia. “With hydraulic valves, there are two routes you can down. You can go with proportional valves, which are heavier, cheaper, and direct drive, so they are efficient but not as high-performing. Or you can go with servovalves, which tend to be two-stage valves with a constant parasitic loss in the pilot stage,” said Carson. “We’re the best of both worlds. We’re direct drive, so we don’t use a pilot stage and don’t have constant leakage. But we have compactness and the reliability of a proportional valve.” The unique servovalve design operates with exceptional performance at very high pressure while minimizing leakage, allowing INEOS Britannia to reduce the boat’s overall weight and minimize aerodynamic drag. “Domin’s servovalves offer the precision, responsiveness, and reliability required to optimize the control systems of our vessel. We are confident that this partnership will help increase performance in the next America’s Cup,” said Ainslie. Domin’s role as a partner to the INEOS Britannia team will continue through the race cycle. Whether providing technical solutions, sending replacement valves on short notice, or analyzing data, the technical team helps the INEOS Britannia team test and develop the
technology to get on the water faster and maximize every minute of preparation. The company was founded with a vision to add value to an industry that seemed to stagnate — where hydraulic designs from the 50s and 60s had been iterated but never revolutionized. Plus additive manufacturing opened up a world of design not possible with conventional manufacturing. Domin could create multifunctional complex components in one part that increases system efficiency or is smaller, lighter, and cheaper to manufacture. “We started to explore a wide range of technologies, such as digital controls, digital electronics, brushless dc motors, and metal 3D printing, in a new, holistic way to design products,” said Carson. “We saw an opportunity to use these technologies to revolutionize an industry worth hundreds of billions of dollars a year, which is huge when you’re a small, potential startup company looking to change the world.” The Domin team spent years forming the company’s foundations, defining its core values, and exploring the depths of hydraulics to decide where they could add the most value. They launched their first product in 2019, focusing on providing high-performance valves that reduce costs and CO2 emissions. “We’re now heavily focusing on systems and subsystems — that’s where we believe the future is. The future goal is to change everything in the hydraulic industry and add more value to the systems,” said Carson. “You have components like pumps that are 95 to 98% efficient, and that’s great. But they must be efficient because the system has many other losses. And the compound loss means these systems are about 20% efficient. So, by making an almost distributed network of electrohydraulic subsystems in one package, we believe we can make these systems 80% efficient. That’s where we believe the future is.”
Shown here is a deconstructed
view of Domin’s servovalve used in INEOS Britannia’s sailboat. | Courtesy of Domin
Domin uses 3D printing technology
for prototyping and to add value to servovalve production. | Courtesy of Domin
FPW
Domin domin.co
www.fluidpowerworld.com
10 • 2023
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DESIGN NOTES Edited by Rachael Pasini • Senior Editor
Hydraulic multicopters have the potential to save lives
The Flowcopter drone can work 24/7 in extreme
conditions with up to 150 kg of payload for shorter relays or up to 500 km with lighter payloads. | Courtesy of Flowcopter
Hard-to-access locations aren’t difficult to come by these days. With wars, natural disasters, and political unrest, people worldwide suffer from wounds, illness, and famine in harsh environments. Though local and global organizations gather food and supplies to deliver to those in need, sometimes the aid can’t get there, or the mission puts crews at risk. Flowcopter, a developer of industrial heavylift drones, has a solution — and it’s based on hydraulics. Before the company was founded, Peter McCurry and Uwe Stein spent about 15 years developing digital displacement technology in Edinburgh at Artemis Intelligent Power, which Danfoss acquired in 2021. At Artemis, McCurry and Stein aimed to solve hydraulics’ most complex problems: 18
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efficiency and control response. Typically, if a hydraulic system is designed for control response, it won’t be efficient. Likewise, if the system is efficient, it won’t respond quickly. So, Artemis developed digital displacement technology to accommodate, and Stein was instrumental in leading the pump development team. They approached market launch a few years ago and focused on mobile off-road machinery. But the team also reevaluated the technology and looked for other possible applications of interest, namely hybrid multicopters. “We were very aware of the limitations of battery electric systems. They’re incredible for some applications, but there are hard electrochemical limitations on what you can do,” said McCurry, Flowcopter’s managing director. “If you accept that you’ve got to carry a battery system when you fly, then you’re going to be really limited with electric aviation in the future.” www.fluidpowerworld.com
They assumed that most systems trying to scale up from small battery electric drones would start looking at hybrid options, such as liquid-fueled engines driven by a net-zero synthetic fuel. And they figured the one rotating shaft on the engine would turn into multiple rotating shafts on the propellers with speed control. However, an electric transmission weighs and costs substantially more than the engine and creates reliability issues when trying to lightweight it for aerospace. “We had a transmission that looked like it might be quite useful for this,” said McCurry, “but we weren’t sure if we had the control bandwidth. So, I led a team at Artemis to build some single-axis test rigs, and they worked pretty much out of the box. We had a controlled response — we could control a single-axis arm that could pivot, control the position, and do a step from one height to another. And all of this was controlled by a digital displacement pump.”
has to work 10 hours a day, seven days a week Flowcopter received a patent to use on the road might fancy taking your truck or in the field, it must be robust, maintainable, the technology for aerospace propulsion and whatever you have in your truck. So, the ability and usable in very harsh environments. So, our raised some capital to build a demonstrator to fly means you avoid damaged infrastructure, basic design is much closer to what you would platform. But the general aerospace audience risky roads, and local situations to deliver the expect in a helicopter but at a much lower wasn’t so convinced. Many industry experts aid where you want it to go.” cost,” said Stein. understood why McCurry and Stein wanted to However, the cost of flying-in aid must be Flowcopter continues experimenting with use hydraulics. Still, they didn’t think hydraulics very low, as the UN World Food Program lacks materials and modifying the design to earn would have fine enough control and fast the budget to send expensive systems into aerospace certification while keeping costs low. enough control response for a multicopter. harsh environments. That’s why Flowcopter’s “2022 was a year to explore the However, once the demonstration platform low-cost transmission technology turns heads. technology and prove that it works. This year, was up and running, Flowcopter caught the “Hydraulics has always been a bit trapped we developed our first product, the FC 100. attention of many big aerospace companies. because it’s seen as a sunset industry by some Next year, we want to go out into the world “There’s a real need for a robust industrial people,” said McCurry. “You talk to people in and engage with pilot customers,” said Stein. solution that sits between drones and drone land, and they don’t know anything about “Our plan is to start small-scale production helicopters, and that’s exactly the market we’re hydraulics or think hydraulics is something you and gain field experience — it might be food trying to address,” said Stein, Flowcopter’s CTO. might find in your grandfather’s tractor.” delivery in South Sudan, crop spraying, or a “In our latest video, you’ll see we can take about Though many intend to electrify, McCurry logistics application. Next year is the year our 130 kg of payload on board. We plan to do more points out that lightweight electric transmissions Flowcopter gets out into the real world.” optimization to increase the payload further.” with exposed copper wires won’t satisfy an The idea is to put the Flowcopter industrial use case running continuously at full drone on a trailer, drive out in the field, and Flowcopter power for 6,000 hours, eight to 10 hours per immediately launch and deliver 100 kg of cargo flowcopter.com day, despite weather conditions. up to 100 km away. “If you want to develop something that “It’s small enough to be mobile but big enough to have a meaningful impact on the area you’re trying to supply,” said Stein. Though the technology can be used for dozens of applications, such as logistics, crop spraying, tree planting, or firefighting, aid delivery is a Standard Parts. Winco. notable application of interest. “We have an Innovate-UK-funded project where we’re working with a company called Air Logistics, which does a lot of work for the UN World Food Program,” said McCurry. “What they see is that any aid delivery is inherently risky. You’re risking crew to operate in austere and uncertain environments. The drone is suited for If you’re driving down a road, that humanitarian missions in road could be blocked. Some people remote locations and harsh FPW
100,000+ Parts
offshore environments, such as wind farms. | Courtesy of Flowcopter
www.jwwinco.com
10 • 2023
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FUNDAMENTALS By Josh Cosford • Contributing Editor
Stop making these beginner hydraulic mistakes you’re talking about. As mentioned above, pressure is simply pressure over a defined area, while force is the energy potential of one object’s interaction with another. In conversation, be sure to describe pressure as pressure and force as force. Don’t be the guy who says your hydraulic press makes “fifty tons of psi.” On the other hand, avoid the misleading exclamation that your power unit operates at “3,000 psi of force.” Force requires a vector (direction), while pressure is a scalar quantity (direction is irrelevant).
If I could time travel back to my early 20s to my job at the car wash, I’d get a kick out of my awe regarding the little hydraulic motor that could pull a track loaded with twelve cars so easily and smoothly through the wash. I was so clueless about hydraulics that I once took the power unit’s pump to a local hydraulic shop to be serviced. Instead of removing the pump, I also brought the entire vertical mount bell housing and tank lid along! I made mistakes, and it’s expected that all beginners make mistakes. But since my official fluid power education began in 2006, I’ve steadily grown and shed the frequency of mistakes. My mistakes now are either advanced or entirely palm-toforehead worthy (like forgetting to join lines on a schematic). But there are mistakes it seems beginners only make, and they’re more common than I’d like. By highlighting these mistakes beginners must stop making, you can kick your hydraulic knowledge up to the next level. 20
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1. Confusing pressure and flow: Let’s get this out of the way and relate pressure to force and flow to speed. Pressure is simply force applied to a defined area (pounds per square inch), so increasing pressure will increase the force at your actuators. I once helped a customer who purchased a pump from an industrial retailer and complained that it now stalled out his gas engine. He admitted he was looking for a larger pump because he wanted his float trailer to lift more weight. Of course, I explained to him that larger pumps make “larger” flow, and he was entirely confused when I recommended a smaller pump. A smaller pump allows you to increase the pressure slightly while using the same input horsepower. Of course, the other components in the system must be rated for the increase, but this tale shows you how this mistake leads to wasted time and money. 2. Confusing force and pressure: The difference here is subtle, and the result of this mistake is generally benign. This mistake affects your reputation more than your machine because it just makes you appear as if you don’t know what www.fluidpowerworld.com
3. Believing that flow makes it go: This mistake comes with a jingle and is probably the most common mistake even more advanced fluid power professionals still make. I, myself, was taught that “flow makes it go, and pressure is resistance to flow.” It’s quite the opposite, and Sir Isaac Newton agrees that all motion results from force, and oil molecules are no different. All pressure starts at the pump, and saying pressure is resistance to flow implies that pressure is higher at the resistance than the source. Pressure can only move from a direction of higher potential to one of lower potential. I’ve written many times about Cosford’s Law, which states: “Pressure makes it go; flow is the rate at which you create pressure.” Once you eschew these three common mistakes, you can open your mind to the true nature of fluid power. Don’t feel bad if you were guilty of making any or all of these mistakes; it just means you’re at the beginning of your journey while on the right path. FPW
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COMPONENT FOCUS Josh Cosford • Contributing Editor
The ins and outs of hydraulic cylinder sensing technologies A sensor is simply a device that can detect the properties of its environment, which could be temperature, pressure or a position in space. We primarily seek to observe hydraulic cylinders’ rods, pistons or attachment’s position in linear space. Designers can choose between digital or analog position sensing. Digital position sensing typically entails a device installed into or on the cylinder to observe end-of-stroke measurement. Designers may wish to know if a cylinder has fully stroked to confirm the first step in a sequential operation. If the PLC, for example, does not read the piston to confirm the end of stroke, an error condition prevents the subsequent operation from beginning, which may otherwise cause severe damage or harm. Consider a tandem press, where which stamps progressively complex shapes into metal parts. If position can’t be confirmed by an upstream press, the entire line must shut down to prevent further errors or even damage. Conversely, a hydraulic designer may need to sense the cylinder fully retracted due to safety concerns, especially with the potential for human interaction and harm. If a jam or failure prevents the complete cycle of a cylinder, material or personnel may be in a position where restarting the cycle would cause damage or harm. In this case, the PLC must know that the cylinder is fully retracted before initiating the next cycle.
Machines like hydraulic presses require the safety and accuracy that sensing technology can provide. | Courtesy of Adobe Stock
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Unlike pneumatic cylinders, and with a few exceptions from some manufacturers, hydraulic cylinders cannot take advantage of reed switches attached to the tie rod to sense a magnetic piston. A reed switch is a magnetically activated switch that is sensitive enough to operate through the aluminum barrel of a pneumatic cylinder. Most often, cylinder manufacturers simply replace the piston’s wear strip with a magnetic strip, although other magnetic rings may also work. However, the magnetic permeability of steel barrels used in hydraulic cylinders prevents the magnetic field from transmitting strongly enough through the barrel. Instead of reed switches, the current end-of-stroke switching standard is the inductive sensor. An inductive sensor uses electromagnetic induction to detect the presence of metal nearby. Also called proximity switches, you may even find them casually referred to as “proxy” or “prox” switches. Regardless of the name, they are powered devices (unlike unpowered reed switches), so you need electrical input such as a 24 V power supply or a 120 Vac input, depending on your choice of hardware. The inductive proximity switch has a probe that inserts into a cylinder’s head and/or cap and fixes in place with a flange. O-rings seal the sensor to prevent hydraulic oil from leaking out, and typically, two bolts to fasten the flange down. The probe must sit less than 2 mm or so away from the metal of the sensing target. That target is predominantly the cushion spear or sleeve of the cylinder unless the manufacturer offers a switch-specific item. In most cases, the sleeve (which resides on the rod side) or spear (protruding from the piston side) are used because manufacturers already offer their cylinders with cushion options, as they’re easy to manufacture and install. One point of note for selecting these inductive proximity switches is that only the external dimensions of cylinders, such as NFPA are standardized; the method of cushioning or sensing could vary widely. You often must select a spacer to help precisely position the probe end within about 2 mm because the spear or sleeve on any given cylinder may be different depths from the head or cap surface. The inductive proxy switch is excellent for end-of-stroke measurement, but what if you want to know intermediate cylinder position, acceleration or velocity? This opens the door for many more options, although each functions roughly the same way. Linear
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Gemco CT959 linear position sensor housing for hydraulic cylinder
MEASUREMENT RANGE: • Magnetostrictive sensors: Suitable for longer measurement ranges, often several meters. • LDTs: Can be used for both short and long measurement ranges, but the maximum range may be limited. • Linear potentiometer: Typically used for relatively shorter measurement ranges, usually a few inches to a few feet, although longer versions are available.
| Courtesy of Ametek
Factory Automation
displacement sensors offer a few methods to achieve the same results, such as an electronic method to relay cylinder stroke position and/or velocity in real-time. The most common linear displacement sensors are magnetostrictive sensors, linear displacement transducers (LDTs) and linear potentiometers. There are many other ways to measure linear displacement, such as optical and hall effect sensors, but the prior three are the most commonly used in hydraulic cylinders. I’ll describe each operation before breaking down the performance advantages and disadvantages of each in the sidebar to the right. Magnetostrictive sensors use the magnetostrictive effect to measure position based on the time it takes for a magnetic pulse to travel along a rod. A built-in controller mounts to the cap (usually at the end, or as a side mount), and a measurement element resides inside a stainless tube in the gun-drilled rod. A contactless magnet mounts to the piston where the sensor can read its position, providing the PLC with one of many analog or digital output options. LDTs use electromagnetic induction principles to measure position by varying the voltage induced in secondary coils as a magnetic core moves within a primary coil assembly. Otherwise, they are similar to magnetostrictive sensors in both appearance and installation. A linear potentiometer is a resistive sensor consisting of a resistive element (a conductive track in this case) and a sliding contact (wiper). This wiper also installs on the piston but is not contactless as the other two options. As the wiper moves along the resistive element, it changes the resistance, which is used to determine position. The mounting of the linear potentiometer is much more flexible since it’s just a few wires attached to a connector you can mount in any convenient location on the cap. As with the prior two, the track requires a gun-drilled cavity within the rod. Once you’ve selected your linear displacement sensor, you are given myriad choices in analog or digital outputs to suit your PLC or controller. The standard 0-5 V, 0-10 V and 4-20 mA may be selected. The first two voltage-based signals are commonly used for industrial automation, while 4-20 mA provides outstanding resistance to electrical noise and faults since the four mA zero-point calibration provides a clearly identifiable zero point not achieved accidentally where short circuits false readings might observe amperage just above zero. Some cylinder-specific control options might include an inverted 20-4 mA or 10-0 V, which, when used on cylinder applications where the natural starting position is fully stroked, and the act of retraction decreases amperage or voltage to indicate a retracted position. Feedback protocol options such as PWM and SSI are not uncommon on LDTs or magnetostrictive position sensors, each providing a different method of precise feedback to your PLC or controller. SSI (Synchronous Serial Interface) is a digital communication protocol that provides absolute position measurement with high resolution and noise immunity but requires more complex wiring than PWM. At the same time, PWM is an analog output method that provides a continuous signal with relative position measurement. It can only offer a change of position but not absolute position detail. However, PWM is simpler to employ and provides excellent dynamic feedback for movement and velocity. FPW
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RESOLUTION: • Magnetostrictive sensors: Offer high-resolution measurements with fine position accuracy, sometimes as fine as one micron. • LDTs: Provide good resolution, although they may be slightly lower than magnetostrictive sensors in some cases. • Linear potentiometer: Offer moderate to good resolution depending on the design and length, but the resolution may not be as high as some magnetostrictive sensors. ACCURACY: • Magnetostrictive sensors: Known for high accuracy and repeatability. • LDTs: Provides accurate measurements still down to less than a thousandth of an inch. • Linear potentiometer: Can offer good accuracy but may be more susceptible to wear and mechanical factors affecting accuracy over time. RESPONSE TIME: • Magnetostrictive sensors: Typically have a fast response time. • LDTs: Offer relatively fast response times. • Linear potentiometer: Response time is generally fast since there are no onboard electronics, which is suitable for dynamic applications. ENVIRONMENTAL FACTORS: • Magnetostrictive sensors: Robust and suitable for harsh environments. • LDTs: Also robust and can handle environmental challenges. • Linear potentiometer: Susceptible to wear and environmental conditions may impact performance, especially in extreme environments, since it requires electrical conductivity across physical connections. And since temperature changes the resistance of metals, extreme heat or cold will affect precision. COST: • Magnetostrictive sensors: Tend to be more expensive. • LDTs: Can be cost-effective. • Linear potentiometer: The most cost-effective solution. 10 • 2023
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ENERGY EFFICIENCY Ron Marshall • Contributing Editor
Compressed air fail: You forgot one thing A meat processing company upgraded its compressed air system to increase capacity and reduce energy consumption. They installed large, premium efficiency VSD
Fig. 1. The old dryer was consuming a constant 150 cfm of purge air, costing $24,000 per year in wasted energy — while processing already dried air.
compressors, a smart compressor controller, efficient filters, large storage, and heated blower desiccant dryers connected with oversized compressor room piping — all in an effort to reduce pressure loss. The maintenance workers showed off the system with great pride. It was saving significant energy, so they should definitely be proud. However, a compressed air auditor looking over the system quickly pointed out that they forgot one thing, and it was costing them thousands of dollars. Lurking in the plant was a heatless desiccant dryer, part of the old system. It was installed remotely because the old compressor room had limited space. There were areas of the plant that operated at near 45° F temperatures. Because of this, they found refrigerated air dryers did not produce dry enough air to prevent water
Fig. 2. The new heated blower dryers were saving significant energy because they were dewpoint controlled. 24
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from condensing in the cold compressed air lines. Compressed air contacted the product, so it had to be desiccant dried to avoid contamination. The old heatless dryer was rated at 1,060 cfml; a dryer of this size in uncontrolled mode will constantly consume 150 cfm of purge air. The new system compressors produced air at 18 kW per 100 cfm specific power, so the energy consumption was about 237,000 kWh costing about $24,000 per year in energy. The sad part of this story is that this old dryer was equipped with an energy management system, but it wasn’t turned on. The plant operators never activated it, even after it was in service for 15 years. For the past two years, the old dryer was drying www.fluidpowerworld.com
already dried air, a flow that was already processed by the new, more efficient heated blower dryers. It took only a few minutes for the powerhouse chief to decide to remove the dryer from service and reduce the waste. Be sure to assess your system after an upgrade to ensure there are no areas of forgotten excess waste! FPW
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The gl o indus bal shippin t g p u r s u ry i s , l i k e a a n d m a r i ne ll ind ing ne u enviro w wa stries y n s , m to bec e n By J o s o t a f l ome m enviro ly frie h ua D i ore ckstei n n dly. Th m e n ta lu b r i c n, Ph.D eu lly a ., Tech i m p a c n t s ( E A L s ) a c c e p ta b l s e n o lo g can m y De ve t in th e lo p m e a a k t push e a ma nt Ma . jor n ag e r , The L u b r i zo
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Industries
around the world are
making sustained efforts to better protect the
acceptable levels of biodegradability, minimal aquatic toxicity and non-bioaccumulative potential. •
environment. That includes the global shipping and marine industry, which today is responsible for an estimated 3% of worldwide greenhouse gases. The International Maritime Organization (IMO) recently set an aggressive target to reduce the carbon intensity of international shipping by at least 40% by 2030 and will seek to achieve a reduction of at least 50% by 2050, compared to levels in 2008. As these goals are pursued, it’s anticipated that alternative fuels will steadily rise in adoption. Biofuels will be attractive because they can be used as a drop-in option — meaning they can help reduce carbon dioxide emissions with limited hardware investment needed for operators. Methanol, liquid natural gas and ammonia — new frontiers for marine applications — are expected to make gains, too. Meanwhile, other measures are set to impact all fluids found throughout major cargo ships. The U.S. Environmental Protection Agency’s (EPA’s) Vessel General Permit (VGP) will soon be replaced with the Vessel Incidental Discharge Act (VIDA), which establishes a framework for the regulation of discharges incidental to the normal operation of a vessel under a new Clean Water Act. Regarding these measures, it’s notable that significant volumes of fluids found on ships — hydraulic fluids, gear oils, greases, and other lubricants — leak into waterways via seepage, spillages and careless disposal every year. Minimizing the impact of such losses has become increasingly critical, and it can be done through the greater proliferation of EALs. Marine original equipment manufacturers and industrial fluid formulators have the opportunity to develop and utilize such fluids in order to maximize environmental protection — read on to find out how. What Are EALs?
As defined by the EPA, EALs have demonstrated www.fluidpowerworld.com
Fluids in marine FPW_vs3.indd 27
•
•
Biodegradability: The capacity of lubricants to be decomposed by microorganisms over time into: ◌ A combination of simpler by-products (primary biodegradation) ◌ Carbon dioxide and water (ultimate biodegradation) Minimal Aquatic Toxicity: Low toxicity to aquatic organisms according to tests defined by the Organization for Economic Cooperation and Development (OECD) and EPA test guidelines. Non-bioaccumulative potential: Low probability of chemical buildup within the tissues of an organism over time.
Marine application opportunities for EALs
Major cargo ships are vast and complex, and are home to dozens of applications where EALs can help improve environmental impact. Hydraulic fluids, gear oils, stern tube lubricants, lubricating fluids, and greases can be found throughout a broad range of important equipment, including: • •
•
Ship engines, responsible for powering the ship across vast distances. Steering and propulsion equipment, including rudders, controllable pitch propellers, stern tubes, fin stabilizers, thrusters, and more. Operational equipment, including deck cranes and winches and cables for maneuvering cargo pods from place to place, along with davits, responsible for lowering and retrieving dinghies and other smaller vessels.
Each of these points represents an opportunity for the fluid to escape into the environment, whether via user error, machine damage, or other events. What’s more, many of them are below the waterline — leakages would necessarily infiltrate the oceans. Given the scale of these ships and the sheer volume of fluids required to keep them operational, loss of such fluids can make a major impact on oceanic and marine life — and minimizing the harm resulting from such losses is increasingly important. 10 • 2023
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SHIPPING VESSELS HAVE NUMEROUS OPERATIONS REQUIRING INDUSTRIAL LUBRICANTS. THIS GRAPHIC HIGHLIGHTS THE MANY FUNCTIONS AND LUBRICANTS USED IN EACH. COURTESY OF LUBRIZOL CORP.
Maintaining elevated performance in EAL formulations
OEMs and fluid formulators, however, do face some challenges when it comes to developing EALs that reliably deliver the kinds of performance required in critical marine applications. For example, a top consideration for any industrial fluid is the protection of equipment. Preventing the premature wear of metal surfaces as they come into contact with each other is a core function of a lubricant — EAL or not. To ensure EALs maintain such performance, specific formulation considerations must be made. For example, one of the most popular reliable classes of anti-wear additives used in conventional fluids and lubricants are zinc dialkyl dithiophosphates (ZDDPs). But because ZDDPs do not naturally biodegrade as necessitated by EAL classifications, formulators cannot use them when developing EAL products. A different type of environmentally acceptable anti-wear additive chemistry must be selected. This hurdle holds true for several other critical performance requirements marine fluids must demonstrate. An industrial gear oil used in a ship’s deck crane, for instance, typically incorporates extreme pressure additives. Sulfurized olefins are another reliable solution for these needs, but like ZDDPs, do not display the biodegradability 28
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required in accordance with EAL standards. In fact, many conventional chemistries frequently used such as demulsifiers, antifoam agents, corrosion inhibitors, friction modifiers, and viscosity modifiers cannot be used in the composition of an EAL. EAL standards further restrict the use of traditional mineral oils due to biodegradability and toxicity concerns. Therefore, synthetic base oil formulations from Groups IV (polyalphaolefins) and V (for example, esters) are required for EALs in place of Groups I, II and III base oils. Opportunity for marine lubricant marketers
Despite the formulation challenges described above, high-performance additives compliant with EAL guidelines are available, and they can be taken advantage of to deliver more environmentally friendly finished fluids to the marine market. And as environmental protection initiatives continue, it is worth the investment to capture growing EAL markets. Research from the consulting and market research firm Kline & Company anticipates that marine EALs will see significant growth potential in the coming years, along with applications in agriculture, construction, mining, and offshore power generation. These applications have high potential for lubricating fluids to impact the surrounding www.fluidpowerworld.com
environment via leakage or mishandling. Demand is expected to be greatest in North America and Europe in the coming years as legislative measures continue to grow more stringent. Hydraulic fluids — including those found in rudders, steering gear, fin stabilizers, thrusters, and more — are expected to be the dominant application for EAL demand, with other applications making up the rest. To capitalize on these needs, working collaboratively with the right partner can be beneficial to develop environmentally certified and performance-validated fluids. A true partner should be able to offer reliable chemical expertise and EAL-compatible solutions, enabling lubricant marketers to expand EAL marine offerings quickly. To those ends, Lubrizol is committed to helping industrial fluids manufacturers find success with new EAL solutions. Demand for EALs only stands to grow in a marine industry that is increasingly concerned with reducing its environmental impact while continuing to reliably serve global markets. For fluid marketers, it is worth investigating EAL solutions that are able to meet environmental standards while maintaining robust performance that the global supply chain depends upon. FPW
Lubrizol Lubrizol.com
www.panolin.com |
| Phone 877 889 2975
M A R I N E
H Y D R A U L I C S
FLUID POWER AT SEA BY JOSH COSFORD, CONTRIBUTING EDITOR
LEARN HOW HYDRAULICS ARE USED IN MARITIME VESSELS AND WHY HYDRAULICS IS THE TECHNOLOGY OF CHOICE.
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HYDRAULICS
have played a vital role in various industries, and the marine sector is no
exception. From small pleasure boats to large ocean liners, hydraulics are extensively used in a wide range of marine applications because of their compact, robust nature. Let’s explore the applications of hydraulics in marine settings, delve into the common hydraulic components used, and discuss why hydraulics are particularly suitable for marine vessels. Steering
Hydraulic systems are the backbone of steering mechanisms on boats and watercraft. These hydraulic steering systems employ one of the few manually operated hydraulic pumps outside reciprocating handpumps. By using hydraulic power, these systems offer precise control and maneuverability, even in challenging conditions. Hydraulic steering systems can transmit high forces, allowing for effortless and responsive navigation, where hydraulic power easily transmits to turn the rudder, ensuring smooth and reliable steering, regardless of the vessel’s size. Sailboats, for example, employ helm pumps constructed similarly to a gerotor motor but instead pump when their shafts are turned. These bi-rotational pumps work in a closed circuit attached to a hydraulic cylinder mounted to the rudder. Hydraulic steering applications highlight a foundational concept of theoretical hydraulics — mechanical advantage. The double-rod cylinder on the rudder ensures linear steering in both directions because displacement is equal. Turning the helm pumps equal fluid into either rod volume of the cylinder, and
Numerous hydraulic cylinders and actuators power equipment on this offshore vessel. Courtesy of Adobe Stock
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force multiplication occurs at a given ratio despite knowledge of the forces involved. For example, let’s assume the volume of our steering cylinder (which tends to be small because of the high power density of hydraulics) is 20 in.3. If we install a helm pump with one cubic inch displacement, we immediately see that our helm requires twenty complete rotations to stroke our steering cylinder fully. Unless you enjoy sailing in tight circles, the rudder is positioned in the middle, leaving only 10 in.3 from the steering cylinder piston. Ten helm rotations in either direction of the center provide a hardover rudder position. Suppose we now observe the ratio of the cylinder (20 in.3) to the helm pump (1 in.3). In that case, we quickly calculate the volume ratio at 20:1. What’s fun about hydraulics is that volume ratios are the same as force ratios. This means that for every pound of force applied to the helm pump, you can expect twenty pounds of force at the steering cylinder. Considering the pump is rotated via the helm, which is often greater than 12 in. in diameter, you can also expect high input force. Anchoring
Hydraulic systems are also employed in anchor handling and winch mechanisms to manage heavy loads efficiently. Hydraulic winches deploy and retrieve anchors, hoist heavy equipment, and handle towing operations despite sometimes
brutal operating conditions. The versatility and reliability of hydraulic systems make them ideal for handling various marine applications that require controlled power and precise control. Hydraulic winches for ships showcase some of the largest hydraulic motors currently produced. With displacement easily topping 3,000 in.3 per rotation, the largest winch systems offer hundreds of thousands of pounds of line pull for applications such as barge handling, escort service, and docking. Lifting and lowering
Marine environments typically require moving and positioning heavy loads, so hydraulic systems are extensively used in cranes and lifts aboard ships and vessels. These systems provide the power needed to lift and lower cargo, offering a high degree of control and safety. Additionally, hydraulic systems can be designed to withstand harsh marine conditions, such as corrosive saltwater and extreme temperatures, ensuring reliable and durable operation. Commercial ships don’t always have boarding doors on the side of their hull, so supplies must be boarded via the gangway or a crane that lifts the supplies off the dock and onto the deck. These are often extendable jib cranes that can lift a few thousand pounds of supplies. A hydraulic cylinder operates the boom, while rotary actuators rotate the crane assembly for precise placement.
Hydraulic cylinders operate booms on marine cranes. Courtesy of Adobe Stock
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Vessel stability
Stability is crucial for marine vessels, especially during adverse weather conditions. Hydraulic stabilizer systems help counteract the rolling motion of a boat, enhancing comfort and safety on board. By using hydraulic actuators, these systems provide instant response and quick adjustments to maintain vessel stability. Hydraulic stabilizers are particularly beneficial in reducing the risk of seasickness and ensuring the well-being of passengers and crew. Stabilizers work by pivoting a fin mounted on each side of the hull, which can respond quickly to counteract waves and wind, keeping the vessel true. Advanced modern systems have sophisticated hydraulic power units to electronically monitor position and adjust the stabilizers quickly to counteract motion. Hydraulic components used in marine vessels
Hydraulic pumps are the heart of any hydraulic system, as they convert mechanical power into hydraulic energy by pressurizing fluid, typically hydraulic oil. In marine applications, pumps are commonly driven by electric motors or engines and come in various types, including gear, vane, and piston designs. The choice of pump depends on the application’s specific requirements and budget. Cylinders and actuators are crucial components that convert hydraulic energy into mechanical force or motion. In marine applications, hydraulic cylinders are used for steering, lifting, and stabilizing tasks. These devices include a cylinder barrel, piston, rod, heads/caps, and seals. When directed to do so, pressurized fluid enters the cylinder, pushing the piston to generate linear force or motion. Hydraulic motors are much like pumps, except they convert incoming hydraulic energy into mechanical torque at their output. Cylinders or motors produce force proportional to their size, although inversely to speed. Hydraulic valves are responsible for directing the flow of hydraulic fluid and regulating pressure in a hydraulic system. They are used in steering systems, winches, and other marine applications to control hydraulic actuators’ direction, speed, and
w
Hydraulic Live Swivels Inline & 90°
Hydraulic winches are commonly used for anchoring, mooring, and towing. Courtesy of Dreamstime force. Valves enable precise and instantaneous adjustments, allowing operators to navigate vessels smoothly and handle loads accurately. Hydraulic systems require suitable hydraulic fluid to transfer power effectively and lubricate internal components. Marine hydraulic systems commonly use mineralbased hydraulic fluids with excellent stability, corrosion resistance, and low-temperature performance. However, in many cases, marine fluid must now be biodegradable in case of an accidental spill, and any responsible captain only uses oils that meet the EPA’s toxicity requirements for marine life. Additionally, hydraulic filters are employed to remove contaminants and maintain the hydraulic fluid’s cleanliness, ensuring the system’s longevity and efficiency. Contamination is the number one cause of failure in hydraulic systems, and when contamination is high, wear particles exacerbate the wear of other components. Nobody wants to be stuck out at sea without steering, so fluid cleanliness practices are always a number-one priority. It should be said that hydraulic components work best when they’re free from corrosion, so where budget permits, avoid components with materials such as aluminum and carbon steel. Materials such as stainless steel or brass are preferred, as they’re better able to resist the corrosive effects of salt water. Why hydraulics benefit marine applications
Hydraulic systems provide a high power-toweight ratio, making them ideal for marine applications with limited weight and space. Hydraulic components’ compact design and high power density allow efficient power transmission without compromising vessel www.fluidpowerworld.com
performance. Hydraulic systems offer precise control and responsiveness, enabling operators to handle marine operations accurately. The ability to vary force and speed, combined with instantaneous response, makes hydraulics highly suitable for steering, lifting, and stabilizing tasks, ensuring the safety and comfort of the vessel and its occupants. Marine environments pose unique challenges due to exposure to saltwater, humidity, and extreme temperatures. Hydraulic systems can be designed with corrosion-resistant materials, seals, and coatings to withstand these harsh conditions, ensuring long-term reliability and minimizing maintenance requirements. Marine hydraulic systems can also incorporate safety features, such as pressure relief valves and fail-safe mechanisms, to prevent overloading and ensure safe operation. Additionally, redundant hydraulic systems can be implemented to provide backup and redundancy, minimizing the risk of system failure and enhancing safety in critical marine applications. For example, if your trim adjustment uses a dc-powered compact hydraulic power unit, the handpump option to manually adjust the trim could be a lifesaver should the power unit’s motor fail. Hydraulics have revolutionized marine applications, providing efficient and reliable power transmission for various tasks on boats and watercraft, from steering systems to cargo handling and stabilization; hydraulics offers robust, precise control, durability, and high power density. Using hydraulic technology, marine vessels can navigate the open seas with enhanced efficiency, safety, and maneuverability, making hydraulics an indispensable component of modern maritime operations. FPW
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SUSTAINABILITY MAKES WAVES IN WORKBOAT SHOW THE INTERNATIONAL WORKBOAT SHOW HIGHLIGHTS SUSTAINABILITY EFFORTS AS IT RETURNS TO THE MORIAL CONVENTION CENTER IN NEW ORLEANS, NOVEMBER 29 - DECEMBER 1. BY MARY C. GANNON, EDITOR-IN-CHIEF
FOR MANY FLUID POWER
users and manufacturers, the final trade show of
the year is the International WorkBoat Show, which returns to the Morial Convention Center in New Orleans, November 29 to December 1. The annual event brings together commercial vessel owners, operators, and builders with the vendors and suppliers that serve them. Nearly 900 companies are poised to exhibit at the event, including about 30 fluid power companies. Fluid power is used heavily in workboats, powering and controlling winches, the boats themselves, offshore wind platforms, and much more.
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Several free education events are available throughout the three-day event’s conference program. As many other trade shows have proven throughout the past year, sustainability is of key importance and Work Boat Show is no different. Topics of note for fluid power engineers and users include: • • • •
Powering the waves: charting a course for electrification of marine technologies The design and construction of the first U.S. electric tug Beyond buzzwords for sustainability in shipyard and port operations Going green: alternative fuels
Additionally, WorkBoat Show features several unique networking opportunities throughout, including: Wheelhouse Tavern — A networking bar right in the middle of the action. The Wheelhouse Tavern is the perfect place to grab a drink, check your emails, and network with your colleagues. Find the tavern at booth #634.
projects, and the best and most efficient ways to work with some of the biggest maritime spenders in the industry. Get answers on contracts, bids, and more in person and in real time. Maritime Throwdown — Watch vessel crew contestants test their skills, physical and mental strength, and endurance. Held in obstacle course format, the contestants compete in a series of physical challenges that may include coiling and lifting heavy lines, carrying, rigging, throwing, and securing lines, all while maintaining safety. This event includes an open bar as well. Significant Boats Awards & Happy Hour — Enjoy drinks with colleagues and friends at Happy Hour to celebrate the innovative owners, builders, and designers behind this year’s 10 Significant Boats and name the 2023 WorkBoat Boat of the Year. *This event must be added on to registration. WorkBoat Pre-Game Party — a happy hour to kick off Thursday Night Saints Football throughout the show floor. FPW
Government Maritime Acquisition Day — A full day of sessions presented by diverse arms of the military outlining upcoming contracts,
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Learn more and register at workboatshow.com.
www.fluidpowerworld.com
Exhibit As Name
Booth #
Bosch Rexroth Corp./Hägglunds 1300 Chevron Lubricants
2029
Coltri Compressors
3760
Dellner Bubenzer
829
DMIC - Delaware Manufacturing Industries Corporation
821
Emerson
821
Hilliard Brake Systems
2352
Ingersoll Rand
1000
JARP Industries
821
John Deere Power Systems
3409, 743
Johnson Brake Systems Johnson Industries Ltd.
1601
Logan Clutch Corporation
2508
Lubriplate Lubricants
1554
Omni Powertrain Technologies
3260
Royal Purple Synthetic Oil
443
Sauer Compressors USA
2351
Shell
3237
Texcel
3718
Transfluid Tube Processing Machinery Inc.
243
Trelleborg Sealing Solutions
2404
Tube-Mac Piping Technologies
1661
Twin Disc Incorporated
3201
Wandfluh of America
821
Wooster Hydrostatics, Inc.
3643
World Wide Metric
1629
Yates Cylinders
3447
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7/27/23 1:36 PM
P N E U M A T I C S
UNDERSTANDING CONNECTED PNEUMATICS AND HOW THEY
BENEFIT MANUFACTURERS In future, updating pneumatic circuits through the IoT will help manufacturers stay current and benefit from the opportunities available to them. MIKE PARZYCH PRODUCT MARKETING MANAGER • NORGREN
Smart,
internet-connected devices have become increasingly significant in all
areas of life, and industry is no exception. The use of automation, artificial intelligence, and advanced analytics are revitalizing manufacturing with new capabilities and operational enhancements, among which are connected pneumatics because of their significant potential for improving performance. For those operations that have depended on pneumatics for years, the addition of connectivity may seem a daunting proposition. But that’s probably because of uncertainty about what information it can provide and how that information can be used to a manufacturer’s advantage. To connect to connected pneumatics, the first step is to understand what they do and what benefits they can provide. 10 • 2023
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Gathering data
Before connected pneumatics can provide any actionable information, they must first connect to something: namely, an industrial network. This network is what enables devices to communicate with one another, receive instructions from the controller, and send data for operators to utilize. Manufacturers may be familiar with the two most common industrial network types — fieldbus and industrial Ethernet — each with its own supported communication protocols that dictate how various devices can communicate. If it is enabled to send data through the network and is compatible with the communication protocol, almost any component of a pneumatic circuit can provide usable and actionable data. Air preparation equipment (ex: filters, regulators, lubricators), valve manifolds, actuator switches, and sensors all can have different types of information to share. Depending on the component, DIAGRAM SHOWS ALL THE COMPONENTS these connected devices can THAT CAN BE USED IN AN IO LINK SYSTEM. COURTESY OF NORGREN measure operating pressure,
For those who have witnessed the capabilities of the internet and smart devices in other contexts, it should come as no surprise that the Industrial Internet of Things (or the use of internet-enabled devices in industry) can offer a great deal of information. What may be less familiar is how exactly that can be accomplished with a pneumatic circuit.
cycle counts, short circuit diagnostics, local temperatures, and more. Even analog devices can be connected to a network by using products, such as input/output blocks, that can translate input and output into shareable data. Ultimately, all this information is sent to a central location for analysis and monitoring. The connected advantage
The collection of information is one thing. But it serves little purpose if it has no substantial impact on the businesses that implement it. In the case of connected pneumatics, the benefits are numerous. One of these benefits is improved machine uptime. Collected data can enable predictive and planned maintenance, reducing unexpected stops in production for urgent repairs. For instance, keeping record of an actuator’s cycle count and performance can provide a more accurate estimate of its service life so that it can be monitored and potentially replaced before failure. Continuous, real-time diagnostics mean that errors can be detected and remedied more quickly, and in the case of failure, sensors can help pinpoint possible causes. Together, these capabilities can help to reduce, and even prevent, costly downtime. And when connected pneumatic circuits are running, they have the potential for
DEMONSTRATION HIGHLIGHTS THE SIMPLICITY OF CONNECTED PNEUMATICS At PackExpo last month, Norgren introduced its newest demo unit — a connected circuit display of IO-Link enabled pneumatic components, which digitally collect and transmit performance data to reduce machine downtime and improve operational productivity. In the unit, an IEPS filter-regulator monitors the pressure. It is connected through an IO-Link Master to a proportional control valve and IO-Link pressure sensor, as well as an IO-Link manifold. Another pressure sensor collects data for the actuator, while additional IO-Link switches tie everything together with the module. Additional components such as dump valves and main air supply are cleanly networked to the system. The whole system provides a dashboard to track the cycles of the actuator, which is being extended and retracted in a simple circuit, said 40
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Bradlee Dittmer, Product Marketing Manager - Valves for Norgren. It provides a clean and visual option to monitoring machine systems. Indicator lights notify the operator of problems with the system. For example, if voltage drops, you will get a notification on the dashboard that the system has failed. Or if pressure drops, the system will send a signal to warn the operator that the pressure is not high enough to actuate the machine. Eventually, if you go below the pressure threshold, the actuator will simply stop working. “It’s just a very simple kind of design, but you’re able to get a lot of the data that’s being collected, transmitting it all through the IO-Link, which typically is either done through EtherCAT, Ethernet IP or Profinet,” Dittmer said. “A lot of customers don’t realize how these components can interact with each other, and the benefit that they can get from it.”
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EXCELON PLUS BOX SET (FRL) FEATURING INTEGRATED ELECTRONIC PRESSURE SENSOR. COURTESY OF NORGREN
greater efficiency as well, with the ability to automate and monitor the function of a system. Blockages or leaks can cause air pressure to drop in a system/circuit and significantly increase air consumption, leading to higher operating costs and contributing to a larger carbon footprint. However, by monitoring operating pressure in real time through connected devices, such as an airline sensor, the system can send an alert when pressure drops below a certain level. This allows measures, such as repairing the leak or changing a filter, to be taken immediately, reducing the impact upon operations. Connectivity can also help to improve productivity. Operational performance metrics can be measured, providing insights of individual parts and the system as a whole. This allows better decisionmaking regarding the best way to maximize productivity — for example, by maintaining optimal air pressure to achieve the desired productivity level. Looking to the future
Shifting to connected pneumatics doesn’t need to be a large undertaking. Manufacturers can start small, by adding a sensor in one part of a circuit and expanding as the benefits are realized. Moreover, establishing connectivity does not need to be difficult: with enabling technologies such as IO-Link, pneumatic devices only need to be plugged in to be ready to use. As industry moves toward the future, updating pneumatic circuits and joining the Industrial Internet of Things will help manufacturers stay current and benefit from the opportunities available to them. FPW
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Material handlers lead the charge to the future
Material handling machines lead the pack in terms of electrification and autonomy, as their compact designs are a perfect fit to test out sustainable options. Edited by Mary C. Gannon, Editor-in-Chief As battery-powered machines continue to grow in the mobile market, one area stands out as an obvious choice for their expansion — mobile material handlers. The smaller size and lower power requirements of mobile material handlers make them well-suited for battery operation. Larger machines, such as heavy construction equipment or long-haul trucks, typically demand significantly more energy, making batteries less practical for their extended operation. Additionally, the versatility and maneuverability of mobile material handlers align with the advantages of electric power sources. Batterydriven systems provide quick and precise control, which is essential for tasks that involve picking, lifting, and transporting loads in confined spaces, like warehouses or shipping yards. This precision is often harder to achieve with the torque and power fluctuations of traditional internal combustion engines. 42
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Finally, because material handlers are often used indoors or in heavily populated urban areas, they can take advantage of the significantly lower noise and vibration levels of battery-operated machines. Here’s a look at two new electrically-powered forklifts on the market. Packing a one-two punch: electric and autonomous
Integrating autonomous functions into batterydriven machines further enhances their efficiency and safety. These systems can be programmed to accurately perform repetitive tasks, reducing the risk of human error and enhancing productivity. Autonomous features can also improve safety by minimizing the need for human operators. To this end, Irish manufacturer Combilift has launched its first autonomous machine. Developed by Combilift ’s t dedicated automation team, ilift's firs T is Comb a is It Combi-AG . e in the Combi-AGT is a 4-wheel ous mach el. autonom d-on mod ctric stan le e l e e electric stand-on model, which is h 4-w the world’s first autonomous dual www.fluidpowerworld.com
operational sideloader for long loads. The Combi-AGT harnesses the very latest smart technology to meet customer demands for driverless sideloader capability. These were driven in part by safety to eliminate the presence of personnel in aisles, consistency in handling procedures and to maximize order fulfilment, while also having a backup manual mode in case of power outages or internet disruptions. Combilift’s automation team has spent three years liaising with specialist steel suppliers to identify the best specifications for the Combi-AGT. The new model, with a lift capacity of 5,000 kg/11,000 lb and various lift heights, addresses the requirements of steel service centers and the metal industries, which typically handle long loads. Combilift worked in tandem with IMR (Irish Manufacturing Research) during the development process to enable seamless integration with multiple client warehouse management systems. Its design is based on the electric manually operated Combi-GTE model which has long been a popular choice for service centers due to its ability to work efficiently in rail guided narrow aisles. The first Combi-AGT unit was supplied to Kansas-based Steel and Pipe Supply 18 months ago, and since then Combilift has collaborated with a number of metal service centers across North America during the development process. The laser-based sensors, fitted at various positions on the chassis, constitute an anticollision safety system, as required by the American National Standards Institute. If the machine senses an obstacle or pedestrian that has entered its path, it automatically slows down and will, if necessary, stop in cases of emergency. It will then continue to drive automatically when the obstacle has cleared its safety sensor area. The enhanced adaptive safety system enables the size of the obstacle detection fields to increase or decrease as per the steer angle and speed of the truck. The natural feature navigation system is superior to traditional methods of truck navigation based on wire guidance or
artificial landmarks such as reflectors. Instead, it uses the naturally occurring features in a warehouse – walls, racking and columns for example, avoiding the need to add to or change the warehouse infrastructure. Its newly developed load dimension detection system (patent pending) operates by performing a laser scan of the load to check that its length matches the task sent to the machine. Similarly, when unloading, it checks that the rack in front has sufficient free space to accept the load. “We have deliberately not rushed into incorporating autonomous products into our portfolio. As with any new launch we have carried out extensive field tests to make sure it is fit for purpose by liaising with a number of leading customers in the metal service industry during the product development stage,” said Combilift CEO and Co-founder Martin McVicar. “We are fortunate to have a very motivated group within our autonomous team of software and mechatronics engineers who are committed to scaling this business unit. The Combi-AGT signals a new milestone in product development with further expansion of our autonomous range in the pipeline.” The AGT features hydraulic actuation and variable-speed programmed routes. It has a 72 V battery and opportune battery charging.
with a 4.6 dB reduction in noise levels. In addition, hydraulic noise at idle state and hydraulic noise during lifting operation were significantly reduced. Battery replacement is simple. A deep drop type battery can be easily and quickly removed and installed (through the side of the forklift) using the fork of a 3.5 ton (or less) forklift or 1.5 ton hand pallet truck with a dedicated pallet, without the need for expensive equipment. When the battery has to be charged after using the vehicle, you directly connect the charger connector to the connector which is separately provided on the left side cover and the charging will begin. The BX series still takes advantage of hydraulics. A state-of-the-art hydraulic control valve controls the hydraulic motor so that its output is in proportion with the movement of the spool detected by a non-contact Hall sensor. It uses SASA sensor-type HPS system in which the output of the hydraulic motor varies in direct proportion to the turning speed of the steering handle and the amount of movement of the lift lever, and a Hall sensor type MCV value which is linked to the load. This ensures high vehicle reliability. FPW
New battery-powered B-X Series forklift from Hyundai.
Reduced energy use with lithium batteries
The new battery-powered B-X Series from Hyundai forklift is complete with truck, lithium battery and charger, with an option to apply a conventional lead acid battery. Available in 5,000-to 7,000-lb capacity, the heart of the B-X Series is a design that dramatically reduces energy consumption to cut the cost of ownership. Plus, the B-X Series can take advantage of Lithium-Ion Battery Technology, that provides longer run times, reduced charging time, and lower energy costs with zero emissions. Throughout these rugged machines are innovative features that improve reliability, simplify servicing, enhance safety, and offer a high level of operator comfort. The machine offers a 17% increase in energy efficiency, www.fluidpowerworld.com
10 • 2023
FLUID POWER WORLD
43
PRODUCT WORLD
Air preparation service units
MS-Basic is a family of pneumatic service units in polymer housings that offer attractively priced components covering most application needs. MS-Basic air preparation components have the functionality to perform the most important technical tasks necessary for proper compressed air preparation and consist of pressure regulators, filter regulators, electric on/off and soft start valves, as well as manual on/off valves with filter/ regulator combinations. The components are fully compatible with the existing Festo MS line of premium service units. Machine builders and enduse customers can combine inexpensive MS-Basic pressure regulators, filter regulators, on/ off and soft start valves with MS series safety valves, lubricators, distributors, filters, and dryers to assemble the best mix of low-cost basic functions with high-end functionality.
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FLUID POWER WORLD
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IO-Link master Emerson has introduced a new Class A, IO-Link master that provides customers with a cost-effective solution for smart and analog sensor connectivity on the Aventics series G3 Fieldbus platform. The G3 IO-Link Master is suitable for machine architectures with many sensors and pneumatic valves, and it’s important to have reliable digital data communication between field devices, such as sensors and the machine controller. Application areas include automotive, tire manufacturing, food and beverage, packaging, and metalworking.
Flow meter with upgraded electronics The CFT20 series flow meters have always incorporated the industry’s desired 4-20 mA outputs and will continue to maintain that output profile (loop-powered / 2-wire). However, DGD is now using a microprocessorbased platform to improve overall repeatability, and increase the operating temperature to 125° C. This new format will mirror the electronics now found in the CFT10 Series which is the voltage output version of the Cartridge Flow meters designed and manufactured in the USA.
Electro-pneumatic pressure regulators series The Type 1000P/1005P/1010P Electro-Pneumatic Pressure Regulators are complete closed-loop servo systems consisting of two solenoid valves, an internal pressure sensor, and electronic controls. Based on analog signal, the pressure is controlled by two solenoid valves to maintain precise pressure: one valve functions as inlet control, the other as exhaust. The pressure output is measured by an internal or an external feedback pressure sensor that provides a feedback signal to the electronic controls. The Type 1000P Electro-Pneumatic Pressure Regulator series is available in 1/8 in. or 1/4 in. NPT porting. Input signals are 4-20 mA, 0-10 V, or RS485 Modbus. Output ranges include 0-30 psig (0-2 bar), 0-60 psig (0-4 bar), and 0-120 psig (0-8 bar). The feedback monitor is internal or external, and monitor outputs are 4-20 mA, 0-10 V or 1-5 V. They feature a wide temperature range of 32° to 158° F (0° to 70° C). The response time is 0.8 seconds with accuracy at +0.1% full scale. Flow rates range from 8 to 2,543 scfh.
www.fluidpowerworld.com
OFCO-F
Pressure transducer
Biodegradable hydraulic fluids
The new KM industrial pressure transducer at 52 mm in length, 19 mm wide in diameter, and weighing less than two ounces, is smaller than Gefran’s existing KH industrial pressure transducer line but offers improved operational and safety features through environmental ratings and additional certifications. The KM series is available in pressure range options of up to 14,500 psi (1,000 bar) and has five electrical connector styles to choose from. By comparison, both the KM and KH provide quick and reliable measurements, shock resistance up to 100 g, and vibration resistance up to 20 g. They also have a linearity best fit straight line pressure accuracy of ±0.15% full scale, an ambient temperature range of -40° to 125° C, and SIL2 certification for electronics.
Proudly Made in the USA ISO 9001:2015 Compliant
Bio-Hydraulic Fluids, Bio-Ultimax 1000, are ultimately biodegradable vegetable-based formulas that replace mineral oil-based hydraulic fluids. They are formulated to perform in hydraulic systems that require Anti-Wear (AW), anti-rust, anti-oxidation, anti-foam, and demulsibility properties. They are highly inhibited against moisture and rusting in both fresh and seawater and pass both A and B Sequences of the ASTM D-665 Turbine Oil Rust Test. Zinc-free additive systems have also been developed that are environmentally friendly and meet or exceed pump requirements. They have a flash point of 450° F for added safety around hot running equipment and are available in various weights, including ISO 32, 46, 68, and 100, for use up to 10,000 psi.
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Call or email our sales team today to discuss your needs • info@ohfab.com • 888.354.0291 • ohfab.com/special-custom-products OFCO-FPW-022023.indd 1
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FZP, FZB, FZD Filter Series Stainless Steel In-line high pressure and Manifold side mounting filters ensure peak protection when operating in corrosive environments. With working pressures up to 6090 psi, 4640 psi, and 5075 psi respectively. PASSION TO PERFORM www.mpfiltriusa.com (215) 529-1300 sales@mpfiltriusa.com
For applications such as: - Process engineering - Water hydraulics - Offshore / Marine hydraulics - High pressure hydraulics - Applications in harsh or aggressive environments
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d. Nonref. In-County Nonrequested Copies Stated on PS Form 3541 (include Total Distribution (Sum of 15c and e) quested (2) Sample copies, Requests Over 3 years old, Requests induced by a Distribution Premium, Bulk Sales and Requests including Association Requests, g. (By Copies (See Instructions to Publishers #4, (page #3))and other sources) Mail not Distributed Names obtained from Business Directories, Lists, and Outside h. the Total (Sum of 15f and g) Mail) Nonrequested Copies Distributed Through the USPS by Other Classes of (3) Mail (e.g. First-Class Mail, Nonrequestor Copies mailed in excess of 10% Requested Limit mailed atCirculation Standard Mail® or Package Services Rates) i. Percent Paid and/or (15c divided by f times 100) Nonrequested Copies Distributed Outside the Mail (Include Pickup Stands, (4) Trade Shows, Showrooms and Other Sources) Electronic Copy Circulation 16. Publication 16. of Statement of Ownership for a Requester Publication is required and will be printed in the issue of this publication. e. a. Total Nonrequested Distribution (Sum of 15d (1), (2), (3) and (4)) Requested and Paid Electronic Copies 17. Signature and Title of Editor, Publisher, Business Manager, or Owner f.
10,936
9,731
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10,735
Total Distribution (Sum 15cPrint and e) b. Total Requested andofPaid Copies (15c) + Requested/Paid Electronic copies (16a)
0
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0
0
0
9,731
9,995
360
200
0
0
0
0
385
386
745
586
10,476
10,581
259
355
10,735
10,936
92.9%
94.5%
0
0
9,731
ALA Industries .......................................9 AutomationDirect ..................... 1, Insert Clippard ...............................................BC Continental Hydraulics ........................13 DMIC ...................................................25 FluiDyne Fluid Power ..........................41 HOF .....................................................37 HydraForce .........................................IBC Hydraulex ..............................................3 J.W. Winco, Inc. ...................................19 Main Mfg ...............................................7 Motion ..................................................5 MP Filtri USA .......................................46 OFCO (Ohio Fabricators) .....................45 Panolin America ..................................19 Spir-Star ...............................................15 Stauff ...................................................38 Super Swivel ........................................33 Tompkins Industries .......................IFC, 7 Veljan Hydrair......................................21 Zero-Max, Inc. .....................................34
Date
9,995
10,476
10,551
92.9%
94.5%
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fluidpowerworld.com
TROUBLESHOOTING CHALLENGE Robert Sheaf • Founder of CFC Industrial Training
Large ram press stutters during extension A company had a press used for forming steel bumpers for large trucks. The circuit was designed with a logic-type prefill valve. This valve was used to bypass the cylinder’s retraction flow of 290 gpm back to tank. It also featured a low-pressure closing spring to reduce any vacuum on extension. The 4-way directional valve only had to be sized to handle 55 gpm to retract the cylinder and provide tonnage after the ram encountered the steel plate. While running production, the ram started to stutter badly on extension but still ran smoothly on retraction. Can you identify what was the problem? We welcome responses of all kinds directly to Robert Sheaf at rjsheaf@cfc-solar.com or to mgannon@wtwhmedia.com. The solution will be provided in conjunction with our December 2023 issue. FPW
Solution to August’s disappearing pump prime after powering off Air bleed valves are a great feature for piston pumps mounted on top of the reservoir. They provide a direct path for air in the system to be pushed back to the tank. Once most of the air is gone, the valve is held closed by hydraulic oil pressure. The fact that the unit ran fine for four weeks and then developed the problem was because the air bleed valve’s standpipe had fallen off of its reservoir location.
48
FLUID POWER WORLD
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www.fluidpowerworld.com
FPW
ESDR-0201A valve driver with HF-Impulse software for IoT-ready control.
Groundbreaking Performance
Plug & Play Simplicity Innercept™ brings unprecedented accuracy, response and valve-tovalve repeatability to proportional control cartridge valve technology. Designed for IoT, it’s the first to feature onboard LVDT servomotion control. Innercept is easy to implement into any system and at a cost far below other servo-valve technologies. See the future of motion control at HydraForce.com/Innercept
Hanover, Germany November 12 – 18 Hall 16, Stand B12
LINCOLNSHIRE, IL, USA 847-793-2300
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© 2023 HydraForce, Inc.
HF Innercept Ad 9x10.875 (FPW) 10-23.indd 1
9/18/23 2:25 PM
Take Control with Cordis E L E C T R O N I C P R E S S U R E R E G U L AT I O N
• Resolution ≤5 mV • Accuracy ±0.25% of full scale • Real-time adjustable PID control • Integrated 0 to 10 VDC, 4-20 mA signal, or 3.3 VDC serial communication
The future of proportional control has arrived— and it’s digital. The Clippard Cordis is a revolutionary microcontroller primed for escape velocity from a proportional control market that has grown stagnant. With unparalleled performance and flexibility not possible with current analog proportional controllers, the Cordis makes everything from calibration, to sensor variety, to future development opportunities more accessible and less complicated.
• 0 to 10 VDC feedback pressure monitor • Virtually silent • No integral bleed required • Multiple pressure ranges from vacuum to 150 psig • 2.7 to 65 l/min flow control
Precise, Linear Digital Pressure Control Contact your distributor today to learn more about how the Cordis can provide precise, real-time control for your application, or visit clippard.com to request more information.
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